Mold-breaking device

ABSTRACT

In a molding operation, sand molds containing castings are conveyed by the cooling conveyor to a mold-breaking station for breaking the molds and releasing the castings. The rectangularly shaped molds and the castings therein are conveyed in a vertical position into an opening with a frame. Fluid actuated cylinders mounting mold-breaking tools are carried by the frame on each of the four sides of the mold. The tools are cruciform in cross section. Upon actuation of the cylinders, the tools simultaneously break into and fracture the sand mold on each side thereof. Further advancement of the conveyor carrying the molds and castings, pushes the fractured mold and castings from the frame onto a shakeout conveyor to complete the breakup of the sand mold whereby the castings can be removed.

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Attorney-Patrick J. Walsh [73] Assignee Bangor Punta Operations lnc.

Greenwich, Conn.

ABSTRACT: In a molding operation, sand molds containing castings are conveyed by the coolin breaking station for breaking the castings. The rectangular] g conveyor to a mol molds and releasing the y shaped molds and the castings therein are conveyed in a vertical position into an opening with a frame. Fluid actuated cylinders mounting mold-breaking tools are carried by the frame on each of the four sides of the mold. The tools are cruciform in cross section Upon actuation of the cylinders. the tools simultaneously break into and fracture the sand mold on each side thereof. Further advancement of the conveyor carrying the molds and castings,

40 4 3mm w I91 s 42 4 Mmd54 1,33, M aw h 2 "M 0. mm m M Wm mm. M Y e h a" NW N mm I K m m" AD m u mm 8m iL m um O S ma 1 I i M -U IF 4 H m 1 U 5U [56] References Cited UNITED STATES PATENTS 7/1916 Loughran...............

astings from the frame onto a pushes the fractured mold and c 164/404 X shakeout conveyor to complete the breakup of the sand mold 34 404 X whereby the castings can be removed. 164/344 X 1,190,434 2,338,781 1/1944 Porter $076,238 2/1963 Rekartmm....................

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M w W! Patented Dec. 14, 1971 3,627,020

3 Sheets-Sheet 1 Patented Dec. 14, 1971 3,627,020

3 Sheets-Shoat I5 Baa-4. M Deco/v6 HINVENTOR.

MOLD-BREAKING lDlEi/lifllli The present invention relates to methods and apparatus for flaskless molding and particularly relates to methods and apparatus for reducing the sand mold to fragments to thereby break out the castings therein.

In a flaskless molding machine, there is provided a moldforming station, a metal-pouring station, a cooling conveyor and a mold-breaking station. At the mold-forming station, sand is disposed in a mold-forming chamber between pattern plates, the sand being compressed by movement of one or both of the pattern plates toward one another to form the mold. The flask is then oriented into position such that the mold can be pushed out from the flask onto a conveyor for movement to the metal-pouring station of the casting machine. After the mold has been formed, it is conveyed to a metal-pouring station where the metal is poured into the mold cavity to form one or more castings. The mold and casting is then conveyed through a cooling section and then to a station for breaking the mold thereby breaking out the casting. Molding machines of the foregoing described type are disclosed in my copending application Ser. No. 74,l6l filed Sept. 21, I970.

It is a primary object of the present invention to provide methods and apparatus for effectively and automatically breaking or sundering the sand molds as the final step of the casting process in order to break the castings out from the mold. To this end, the molds, after leaving the cooling section, are conveyed through the mold breaker which includes inner and outer frame portions the inner frame portion having a suitably shaped opening for receiving the molds. On each of the four sides of the outer frame portion, there is provided a fluid actuated cylinder carrying a mounting plate which, in turn, carries mold-breaker tools or heads. Each mounting plate is slideably carried by the outer frame to advance and retract the tools carried thereon through the inner frame into and out of the inner frame opening. The mold-breaker heads are cruciform in cross section with their axes paralleling their direction of movement, the inner frame having like formed slots to permit the heads to pass therethrough.

When a mold is disposed within the frame opening of the mold breaker, the mounting plates are simultaneously move toward the mold with the breaker heads passing through the inner frame slots to penetrate and fracture the sand mold. Upon movement of the backing plates and heads away from the mold and advancement of the fractured mold through the mold breaker opening, the fractured mold is discharged onto a conveyor having a grated surface. The dumping of the fractured sand mold from the mold breaker onto the grated conveyor causes further disintegration of the fractured sand mold, the sand passing through the grated conveyor for reprocessing and the castings, released from the mold, being carried by the grated conveyor to further processing stations. The foregoing operation is automatic and the movement of the breaker heads into the molds is limited such that the castings per se are not engaged by the breaker heads when the mold is being fractured.

It is another object of the present invention to provide methods and apparatus for sunden'ng molds to break out castings therefrom without damaging the castings per se.

it is a related object of the present invention to provide in a flaskless molding machine efficient and-inexpensive methods and apparatus for sundering molds and retrieving castings.

These and further objects and advantages of the present invention will become more apparent upon reference to the following specification, appended claims and drawings wherein:

H6. 1 is a fragmentary perspective view of a portion of a molding line illustrating a mold breaker therefor constructed in accordance with the present invention;

FIG. 2 is a side elevational view of the mold breaker illustrated in H6. l;

FIG. 3 is an end elevational view of the mold breaker illusmated in FIG. 2 looking from right to left therein;

FIG. d is an end elevational view similar to FIG. 3 illustruting the fracturing of the sand mold by the breaker heads;

H6. 5 is a side elevational view similar to H6. 2 illustrating the discharge of the fractured sand mold onto the breaker apron;

FIG. 6 is a fragmentary perspective view of one the breaker heads;

FIG. 7 is a detail view of one side of the inner frame; and

HG. h is a modification of the present invention illustrating in side elevation the mold breaker mounted for adjustable positioning with respect to molds.

Referring now to the drawings, particularly to FIG. ll, there is disclosed the terminus of a molding line comprising a conveyor section generally indicated at lift, a mold breaker generally indicated at H and a mold sand and casting receiving conveyor generally indicated at M. As will be appreciated, the molds M are advanced along conveyor W in the direction of the arrow illustrated in H6. ll from a cooling station, now shown, wherein the molten metal poured into the mold cavities through the gating system is cooled and set. The molds indicated at M includes mold cavities llti inset along butting faces. Thus, each mold M as it moves toward the moldbreaker station i2 carries a casting with the next adjacent mold m. In the illustrated form, each mold M contains four cavities on opposite faces which register and cooperate with four cavities formed on the next adjacent molds to form four castings, the castings illustrated comprising brake drums. It will be appreciated that the molds M may be conveyed intermittently as desired through the metal pouring, cooling, and the mold-breaker stations.

Particularly, the mold-breaker station 12 includes a structural outer frame 11h completely encompassing or surrounding the terminal portion of conveyor 10 and an guide frame 20 defining an opening 21 for receiving the molds M from conveyor 110. Outer frame lid is comprised] of top, bottom and side frame members Ida-d suitably secured to one another at their comers. Inner frame 20 is suitably carried by a plurality of right-angle brackets 22 located at the comers thereof, the brackets 22 being, in turn, suitably secured to the corners of the frame members Eda-d. Each member of outer frame K8 is centrally recessed along its inner face to provide an opening 24lad corresponding with inner frame 20. ln each opening ZAa-d, there is disposed a mounting plate 26 carrying a pair of guide rods 2d at opposite ends thereofifor sliding movement in bushings 30 provided in the associated frame member 118. plates 26 are thus mounted for movement toward and away from inner frame 20.

To provide for movement of each of the heads 26 a fluid actuated, preferably hydraulic, cylinder 32 is fixed on the outer face of each outer frame member, its piston rod extending through a central opening in the frame member for connection with the corresponding head 26.

As best seen in F110. 3, a plurality of mold-breaker tools or heads M project from the inner faces of breaker heads 26, and, in the retracted position thereof, lie without the opening 211. As illustrated in FIG. 6, the breaker tools 34 are cruciform in cross section and are carried on rods 36 which are suitably secured to mounting plates as. The tools 34 are aligned in a single row along the inner face of each mounting plate 26, three tool heads being carried by each of the mounting plates in the illustrated form hereof. Suitably shaped slots 19 are formed through the inner frame 20 in registry with tools 34 to permit the tools 3A to pass into and out of opening 21.

it will be appreciated that breaker tools 34 are thus arranged on each of the four sides of mold M when the latter lies in opening 21 and are movable through the slots 19 in inner frame 20 to fracture the mold M. The brackets 22 provide stops limiting the extent of inward movement of mounting plate as whereby tools 34 penetrate the molds only to a limited extent. As illustrated in FIG. 5, there is provided a discharge apron 3% which slopes downwardly such that the mold and castings discharged from the mold breaker 12 are disposed on the grated conveyor M.

in use. molds M are moved along conveyor l0 toward mold breaker Ill and. when a mold is received in the opening 21 within the frame 20 in a position fully encompassed on all sides by the breaker tools; 34, fluid cylinders 32 are actuated to move the mounting plates 26 and hence tools 34 toward the molds M. The cruciform tools 34 extend through the slots 19 in the inner frame 20 and penetrate and fracture the sand molds as particularly illustrated in FIG. 4. By orienting the cruciform tools on each of the sides of the mold and by form ing the tools in a cruciform shape, fractures are set up in three directions, that is, longitudinally, transversely and vertically, throughout the full extent of mold M insuring a complete sundering of the mold when disposed on the grated conveyor 14.

Further, the inner frame 20 maintains the fractured mold in its rectangular mold shape until conveyor has advanced the unbroken molds M toward breaker 12 sufficiently to push the fractured mold from frame onto apron 38. On apron 3 8, the mold begins to break up with the final fracture and sundering being accomplished by the disposition of the mold on the grated conveyor 14. As seen in FIG. 1, the castings C are thus broken out from the mold with the mold being completely crumbled. The crumbled mold parts and loose sand may then pass through the grated conveyor 14 for collection and reprocessing while the castings are conveyed to other stations, no shown, for further processing.

In a modification of the present invention, shown in FIG. 8, the mold breaker 112 is adjustably mounted at the terminal portion of the conveyor 110 to provide for precise registration of the mold breaker with each mold M on the conveyor. In manufacturing different castings mold dimensions will vary according to the type and size of casting being made during a foundry run. It is desirable to provide machine adjustments to accommodate different operating conditions particularly in respect of mold dimensions.

Referring to FIG. 8, the mold breaker 112 is adjustably mounted with respect to the terminal portion of conveyor 110 by means of guide rods 113 located on both sides of the conveyor 110. The mold breaker 112 is moved in timed relation to the movement of molds M so that the mold breaker assumes a final position adjacent and in registry with the mold located at the end of the conveyor. In this manner the mold breaker will engage and break the mold to release the casting without disturbing the next adjacent mold on the conveyor.

The mold breaker 112 cooperates with a notch 115 molded in the surface of the molds for purposes of controlling and registering the mold with the mold breaker. As relative movement occurs between the molds M and the mold breaker, a sensing switch 125 will encounter the notch in the surface of the molds and thereby stop the mold breaker in registry with the first mold in line. The sensing switch controls a suitable valve 117 between the cylinder 127 and the power unit 123 which typically is a hydraulic pump. The hydraulic pump powers a fluid cylinder 127 to move the mold breaker along guide rods 113. The fluid cylinder is connected to the mold breaker by a suitable bracket. The mold breaker 112 is furnished with guide rods 128 and cylinders 132 for breaking molds as described above.

The preferred method of operation is as follows. After a mold is cracked and its casting released, the cooling conveyor moves the line of molds to position the next mold at the breaking station. As the molds move downstream, the mold breaker moves upstream a distance sufficient to pass the notch 115 located between the two molds at the end of the conveyor. The upstream movement of the mold breaker is preferably controlled by the sensing switch 125 which when in the up" position initiates the valve and cylinder action to move the mold breaker a predetermined distance upstream. The up" position of switch 125 is shown in broken lines in FIG. 8.

When the molds stop and are stationary, the mold breaker moves downstream until the sensing switch encounters the notch at which point the mold breaker stops in registry with the first mold in line. The mold then is cracked to release its casting and the cycle is repeated.

The invention may be embodied in other specific forms without de arting from the s irit or essential characteristics thereof. e present em lment IS therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

What is claimed is:

1. Apparatus for breaking flashless sand molds and breaking out the castings contained therein comprising, a frame having an opening for receiving the molds, mold-breaking tools carried by said frame on at least two sides thereof for movement into and out of the mold-receiving opening, means for moving said tools into and out of said opening, said tools being adapted to penetrate and fracture the molds when moved into said opening.

2. Apparatus according to claim 1 wherein said tools are cruciform in cross section with their axes lying parallel to their direction of movement into and out of said opening.

3. Apparatus according to claim 1 wherein said tools are carried on next adjacent sides of said frame.

4. Apparatus according to claim 1 wherein said tools are carried on oppositely disposed sides of said frame.

5. Apparatus according to claim 1 wherein said frame defines a polygonally shaped opening, said tools being carried on each of the sides of the frame for movement into and out of said opening.

6. Apparatus according to claim 1 wherein said tools are cruciform in cross section with their axes lying parallel to their direction of movement into and out of the opening, a plurality of said cruciform tools spaced one from the other along each side of said framework.

7. Apparatus according to claim 6 wherein said moving means includes a fluid actuated cylinder.

8. Apparatus according to claim 7 including means for conveying the molds through the opening, a grate disposed below the opening on its discharge side to receive the fractured sand mold and castings.

9. Apparatus for breaking flashless sand molds and releasing the castings contained therein comprising a mold-breaking frame having an opening for receiving the molds, means for moving the molds into said opening, means for mounting said frame for movement parallel to the line of movement of the molds, means for moving the frame, and means for positioning the frame in registry with a mold located on the moldmoving means.

10. A method of using a mold-breaking machine having a frame defining an opening for receiving sand molds and a plurality of opposed mold-breaking tools mounted in said frame for movement into and out of the mold-receiving opening, break out the castings contained in flashless sand molds comprising the steps of; successively locating the molds in the opening defined by the frame, advancing the tools into said opening to penetrate and fracture the molds disposed therein, retracting the tools from said opening, and discharging the fractured molds and castings from the mold breaker.

11. The method according to claim 10 including the step of discharging the fractured molds onto a grated conveyor to permit the sand to pass through the conveyor and conveying the castings away from the mold breaker. 

1. Apparatus for breaking flashless sand molds and breaking out the castings contained therein comprising, a frame having an opening for receiving the molds, mold-breaking tools carried by said frame on at least two sides thereof for movement into and out of the mold-receiving opening, means for moving said tools into and out of said opening, said tools being adapted to penetrate and fracture the molds when moved into said opening.
 2. Apparatus according to claim 1 wherein said tools are cruciform in cross section with their axes lying parallel to their direction of movement into and out of said opening.
 3. Apparatus according to claim 1 wherein said tools are carried on next adjacent sides of said frame.
 4. Apparatus according to claim 1 wherein said tools are carried on oppositely disposed sides of said frame.
 5. Apparatus according to claim 1 wherein said frame defines a polygonally shaped opening, said tools being carried on each of the sides of the frame for movement into and out of said opening.
 6. Apparatus according to claim 1 wherein said tools are cruciform in cross section with their axes lying parallel to their direction of movement into and out of the opening, a plurality of said cruciform tools spaced one from the other along each side of said framework.
 7. Apparatus according to claim 6 wherein said moving means includes a fluid actuated cylinder.
 8. Apparatus according to claim 7 including means for conveying the molds through the opening, a grate disposed below the opening on its discharge side to receive the fractured sand mold and castinGs.
 9. Apparatus for breaking flashless sand molds and releasing the castings contained therein comprising a mold-breaking frame having an opening for receiving the molds, means for moving the molds into said opening, means for mounting said frame for movement parallel to the line of movement of the molds, means for moving the frame, and means for positioning the frame in registry with a mold located on the mold-moving means.
 10. A method of using a mold-breaking machine having a frame defining an opening for receiving sand molds and a plurality of opposed mold-breaking tools mounted in said frame for movement into and out of the mold-receiving opening, to break out the castings contained in flashless sand molds comprising the steps of; successively locating the molds in the opening defined by the frame, advancing the tools into said opening to penetrate and fracture the molds disposed therein, retracting the tools from said opening, and discharging the fractured molds and castings from the mold breaker.
 11. The method according to claim 10 including the step of discharging the fractured molds onto a grated conveyor to permit the sand to pass through the conveyor and conveying the castings away from the mold breaker. 